Bedding article with material to absorb/desorb moisture and/or moisture vapor to actively cool the article and method of making an article

ABSTRACT

A bedding article has a fabric having a substrate having a surface area. The fabric has a polymeric material that absorbs and desorbs moisture and/or moisture vapor that results in a catalytic action to actively cool the substrate or fabric. The material covers about 40% to about 70% of the surface area of the substrate and as present on the substrate is present at 0.5 to 1.0 grams per square meter.

CROSS-REFERENCE TO RELATED APPLICATION DATA

This application claims the benefit of and priority to Provisional U.S. Patent Application Ser. No. 62/476,518, filed Mar. 24, 2017, titled, BEDDING ARTICLE WITH MATERIAL TO ABSORB/DESORB MOISTURE AND/OR MOISTURE VAPOR TO ACTIVELY COOL THE ARTICLE AND METHOD OF MAKING AN ARTICLE

BACKGROUND

Bedding articles such mattress pads and toppers, pillow covers and cases, sheets, comforters, comforter covers and the like are typically made from cotton, polyesters, and like materials and blends of these materials. The materials are developed and used to promote comfort when relaxing or sleeping. These materials can, however, absorb and retain heat and moisture. This can make an otherwise comfortable sleeping or resting experience less comfortable.

Accordingly, there is a need for a material for bedding articles having a polymeric material that can absorb/desorb moisture and/or moisture vapor to actively cool the article. Desirable, such a material also allows air flow through the material for “breathability.”

SUMMARY

A bedding article is fabricated from a fabric having a substrate having a surface area. The fabric has thereon a material that absorbs and desorbs moisture and/or moisture vapor resulting in a catalytic action that actively cools the substrate or fabric. In an embodiment the material is a polymer. In an embodiment, the material is present so as to cover about 40% to about 70% of the surface area of the substrate. The material can cover a first portion of the substrate at one coverage percentage and another portion of the substrate at a different coverage percentage.

In an embodiment, the substrate is a hydrophobic synthetic material. The substrate can be one or a combination of nylon, polyester, polypropylene and the like. In an embodiment the substrate is a blend that includes a natural material. The natural material can be one or a combination of cotton, wool and silk. The substrate can be a blend of a hydrophobic synthetic material and a natural material, in which the hydrophobic material is present at at least 50% by weight of the substrate. In an embodiment, the hydrophobic synthetic material is present at about 60% by weight of the substrate.

The absorbs and desorbs moisture and/or moisture vapor resulting in a catalytic action that actively cools the substrate or fabric as dried on the substrate is about 0.5 to about 1.0 grams per square meter (gsm). In an embodiment, the material is a polymer. It can be a combination of one or more elastomeric styrenic block copolymer that is optionally functionalized with functional groups different from sulfonic acid or sulfonated ester functional groups, and one or more sulfonated block copolymer. The material can be a phase change material.

In an embodiment the bedding article is a mattress pad, a mattress topper, a pillow, a pillow cover, a pillow case, a bed sheet, a comforter, a comforter cover and the like.

The bedding material can be present on the substrate as a plurality of discrete elements. The discrete elements can have a snowflake shape, a propeller shape or any of a variety of shapes. In embodiments in which the shape has a center portion, the material is present in the center portion; that is, the center portion is filled. In an embodiment, the material is present on the substrate in a continuous pattern, such as a straight continuous pattern, a curvilinear continuous pattern or the like.

Other objects, features, and advantages of the disclosure will be apparent from the following description, taken in conjunction with the accompanying sheets of drawings, wherein like numerals refer to like parts, elements, components, steps, and processes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example of a mattress pad having an embodiment of an elongate pattern of material elements formed from a material that absorbs and desorbs moisture and/or moisture vapor that actively cools the substrate or fabric;

FIG. 2 is a perspective view of an example of a pillow having a different elongate pattern of material elements;

FIGS. 3-5 are illustrations of a portion of fabric having an embodiment of a pattern of discrete elements formed having various snowflake shapes; and

FIGS. 6 and 7 are illustrations of a portion of fabric having another embodiment of a pattern of discrete elements formed having various propeller shapes.

DETAILED DESCRIPTION

While the present disclosure is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described one or more embodiments with the understanding that the present disclosure is to be considered illustrative only and is not intended to limit the disclosure to any specific embodiment described or illustrated.

Referring now to FIG. 1 there is shown in perspective view, an example of a mattress pad or mattress topper formed from a fabric having thereon a material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric. The illustrated mattress pad fabric has the material applied to a substrate (the principal fabric from which the bedding article is manufactured) in a straight or linear window pane pattern. The underlying or substrate material can have certain desired characteristics for the intended use of the bedding product. For example, the substrate can be a breathable, moisture permeable and/or wicking material if so desired, or it can be an air and moisture impermeable material depending upon the intended use of the article.

In an embodiment the substrate or base material is a hydrophobic synthetic material such as nylon, polyester, polypropylene and the like. The substrate can be a substantially hydrophobic material blend that includes a synthetic material and a natural (organic) material, such as cotton, wool, silk and the like. In an embodiment the substrate is a blend of about 60 wt % to about 100 wt % synthetic material and about 0 wt % to about 40 wt % natural material.

A suitable material that absorbs and desorbs moisture and/or moisture vapor that results in a catalytic action that actively cools the substrate or fabric (referred to herein as “the material”), is a material that when applied and dried or cured forms an elastic, moisture vapor permeable applique or film on the substrate. The material can be a polymer. It can be a hygroscopic polymeric material. The absorb and desorb process induces a catalytic reaction in the polymer that actively cools the substrate and/or fabric.

A suitable material is a combination of one or more elastomeric styrenic block copolymers that is optionally functionalized with functional groups different from sulfonic acid or sulfonated ester functional groups, and one or more sulfonated block copolymer. Other suitable materials include phase change materials that can absorb and release an increased amount of energy at the temperature at which the phase change occurs, while at the same time, reducing or stopping the flow of thermal energy (temperature change). That is, the material can heat up or cool down as it approaches the phase change temperature, but does not significantly change temperature as the phase change occurs, and the material may be an effective barrier to thermal energy until the total latent heat of the material is absorbed or released during heating or cooling. The thermal energy can be stored or removed from material and can be recharged by a source of heat or cold. The material, which can be a polymer, absorbs and desorbs moisture and moisture vapor resulting in a catalytic action that actively cools the substrate or fabric.

Suitable materials can be selected to meet the desired characteristics for a particular application. Multiple materials may also be used to effect various desired characteristics. Suitable materials are those disclosed in Flood, et al., U.S. Pat. No. 9,394,414, and Araujo, et al., U.S. Pat. No. 9,062,913. One suitable material is KRATON® brand thermoplastic rubber commercially available from Kraton Polymers US of Houston, Tex.

In an embodiment, the coverage of the material on the fabric is about 40% to about 70% of the surface area of the fabric. The coverage percentage or density can vary on the material. For example, it may be desirable for one area of the fabric to have a coverage of 50% while another area of the fabric has a coverage of 60%. The weight of the material as dried on the fabric is about 0.5 to about 1.0 grams per square meter (gsm).

As noted above, patterns for application of the material to the substrate can vary. Elongated elements of the material are illustrated in FIG. 1, in which the elements form a straight windowpane shape, and in FIG. 2 in which the elongated elements form a curvilinear windowpane shape. FIGS. 3-5 illustrate various discrete snowflake pattern elements of the material on the substrate. The snowflake can take a variety of shapes and sizes, as do natural snowflakes. In each, the center of the snowflake is filled, that is the center of the snowflake contains the material

FIGS. 6 and 7 illustrate various discrete propeller shapes of the material on the substrate. The illustrated propellers are three-bladed propellers, but any number of blades can be present. Again, the center or hub of the propeller is filled and contains the material. Inset in FIG. 7, is an isolated illustration of two propeller shaped elements showing one embodiment of the dimensions of the elements (about 8 mm×8 mm).

In methods of fabricating the fabric, the material is applied to the substrate in one of a variety of ways, including, for example, hot or cold adhesive, heat pressing, welding and printing. One way in which the material is applied to the substrate is a printing method, such as a gravure printing method, such as an aluminum foil gravure printing method. In one method, a modified wide-width aluminum foil gravure printer has a print roller with the desired pattern of elements etched to a depth of equal to or greater than about 150 microns. In an embodiment, the etching is to a depth of about 160 microns. The material is applied as a liquid or slurry and is allowed to dry or cure.

It will be appreciated that the present material, fabric, bedding articles and method of fabricating the fabric and bedding articles provide a fabric and bedding article that absorbs and desorbs moisture and/or moisture vapor resulting in a catalytic action that actively cools the substrate or fabric while still remaining flexible. This allows for use of the fabric in bedding articles without sacrificing comfort. That is, the material as applied will not create hard or inflexible regions in the bedding article that could otherwise feel scratchy or irritate a user. It will also be appreciated that the fabric can be used on an outwardly oriented surface, a surface that is in contact with the user's body such as a bed sheet, or on an inwardly oriented surface, a that is on an inside of, for example a pillowcase, comforter or comforter cover or the like.

It will be appreciated by those skilled in the art that the relative directional terms such as top, bottom, sides, front, rear and the like are for explanatory purposes only and are not intended to limit the scope of the disclosure. All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure.

In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.

From the foregoing, it should also be understood that various changes and modifications to the presently disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. 

1. A bedding article, comprising: a fabric having a substrate having a surface area, the fabric having thereon a material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric.
 2. The bedding article of claim 1 wherein the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric is present so as to cover about 40% to about 70% of the surface area of the substrate.
 3. The bedding article of claim 1 wherein the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric is present so as to cover a portion of the substrate at about 40% to about 70% of the surface area of the portion of the substrate and wherein a different portion of the substrate has the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric present so as to cover the different portion of the substrate at about 40% to about 70%, but at a different coverage percentage than the first portion of the substrate.
 4. The bedding article of claim 1 wherein the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric as dried on the substrate is about 0.5 to about 1.0 grams per square meter (gsm).
 5. The bedding article of claim 1 wherein the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric is a combination of one or more elastomeric styrenic block copolymer that is optionally functionalized with functional groups different from sulfonic acid or sulfonated ester functional groups, and one or more sulfonated block copolymer.
 6. The bedding article of claim 1 wherein the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric is a phase change material.
 7. The bedding article of claim 1 wherein the bedding article is one of a mattress pad, a mattress topper, a pillow, a pillow cover, a pillow case, a bed sheet, a comforter and a comforter cover.
 8. The bedding article of claim 1 wherein the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric is present as a plurality of discrete elements on the fabric.
 9. The bedding article of claim 1 wherein the discrete elements have a snowflake shape.
 10. The bedding article of claim 9 wherein a center portion of the snowflake is formed so as to have the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric.
 11. The bedding article of claim 1 wherein the discrete elements have a propeller shape.
 12. The bedding article of claim 11 wherein a center portion of the propeller is formed so as to have the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric.
 13. The bedding article of claim 1 wherein the material that absorbs and desorbs moisture and/or moisture vapor to actively cool the substrate or fabric is present on the substrate in a continuous pattern.
 14. The bedding article of claim 13 wherein the continuous pattern is a straight continuous pattern.
 15. The bedding article of claim 13 wherein the continuous pattern is a curvilinear continuous pattern.
 16. The bedding article of claim 1 wherein the substrate comprises a hydrophobic synthetic.
 17. The bedding article of claim 16 wherein the substrate comprises one or a combination of one or more of nylon, polyester, and polypropylene.
 18. The bedding article of claim 16 wherein the substrate is a blend that includes a natural material.
 19. The bedding article of claim 18 wherein the natural material comprises one or a combination of one or more of cotton, wool and silk.
 20. The bedding article of claim 1 wherein the substrate comprises a blend of a hydrophobic synthetic material and a natural material, the hydrophobic material present at at least 50% by weight of the substrate.
 21. The bedding article of claim 20 wherein the hydrophobic synthetic material is present at about 60% by weight of the substrate. 